Method of manufacturing a liquid crystal device utilizing a liquid organic semiconductor for the active layer

ABSTRACT

An LCD device and a method for fabricating the same is disclosed that improves a yield by decreasing processing time. The LCD device includes gate and data lines formed substantially perpendicular to each other on a substrate and defining a unit pixel region; a thin film transistor formed at a crossing of the gate and data lines; an active layer formed over the gate line, the data line, and the thin film transistor; an organic resin formed on a portion of a gate insulating layer not including the gate line, the data line, and the thin film transistor; a passivation layer formed on an entire surface of the substrate including the thin film transistor; and a pixel electrode, formed in the unit pixel region, the pixel electrode being connected with a drain electrode of the thin film transistor.

This application claims the benefit of the Korean Patent Application No. P2005-0037874, filed on May 6, 2005, which is hereby incorporated by reference as if fully set forth herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a liquid crystal display LCD device, and more particularly, to an LCD device and a method for fabricating the same to improve a yield with a decreased process time.

2. Discussion of the Related Art

Recent efforts have been made to research and develop various types of flat display devices, such as liquid crystal display (LCD), plasma display panel (PDP), electroluminescent display (ELD), and vacuum fluorescent display (VFD). Some types of flat display devices have already been used as displays in various applications.

Among the types of flat display devices, liquid crystal display (LCD) devices have been most widely used due to its advantageous characteristics of thin profile, lightness in weight, and low power consumption, whereby the LCD devices provides a substitute for a Cathode Ray Tube (CRT). In addition to mobile type LCD devices such as a display for a notebook computer, LCD devices have been developed for computer monitors and televisions to receive and display broadcasting signals.

Despite various technical developments in the LCD technology having applications in different fields, research in enhancing the picture quality of the LCD device has been, in some respects, lacking as compared to other features and advantages of the LCD device. In order to use LCD devices in various fields as a general display, the key to developing LCD devices depends on whether LCD devices can realize a high quality picture, such as high resolution and high luminance with a large-sized screen, while still maintaining lightness in weight, thin profile, and low power consumption.

Generally, the LCD device includes an LCD panel for displaying a picture image, and a driving part for applying a driving signal to the LCD panel. The LCD panel includes first and second glass substrates being bonded to each other at a predetermined interval therebetween, and a liquid crystal layer formed between the first and second glass substrates by injection of liquid crystal.

The first glass substrate (TFT array substrate) includes a plurality of gate and data lines, a plurality of pixel electrodes, and a plurality of thin film transistors. The plurality of gate lines are formed at fixed intervals in a first direction on the first glass substrate, and the plurality of data lines are formed at fixed intervals in a second direction perpendicular to the first direction. Then, the plurality of pixel electrodes, which are arranged in a matrix-type configuration, are respectively formed in pixel regions defined by the plurality of gate and data lines crossing each other. The plurality of thin film transistors are switched according to signals of the gate lines for transmitting signals of the data lines to the respective pixel electrodes.

The second glass substrate (color filter substrate) includes a black matrix layer that excludes light from regions except the pixel regions of the first substrate, R(red)/G(green)/B(blue) color filter layer displaying various colors, and a common electrode to obtain the picture image. In a case of an In-Plane Switching (IPS) mode LCD device, the common electrode is formed on the first glass substrate.

Next, a predetermined space is maintained between the first and second glass substrates by spacers, and the first and second substrates are bonded to each other by a seal pattern having a liquid crystal injection inlet. At this time, the liquid crystal layer is formed according to a liquid crystal injection method, in which the liquid crystal injection inlet is dipped into a vessel having liquid crystal while maintaining a vacuum state in the predetermined space between the first and second glass substrates. That is, the liquid crystal is injected between the first and second substrates by an osmotic action. Then, the liquid crystal injection inlet is sealed with a sealant.

Meanwhile, the LCD device is driven according to the optical anisotropy and polarizability of liquid crystal material. Liquid crystal molecules are aligned using directional characteristics because the liquid crystal molecules each has long and thin shapes. In this respect, an induced electric field is applied to the liquid crystal for controlling the alignment direction of the liquid crystal molecules. That is, if the alignment direction of the liquid crystal molecules is controlled by the induced electric field, the light is polarized and changed by the optical anisotropy of the liquid crystal, thereby displaying the picture image. In this state, the liquid crystal is classified into positive (+) type liquid crystal having positive dielectric anisotropy and negative (−) type liquid crystal having negative dielectric anisotropy according to electrical characteristics of the liquid crystal. In the positive (+) type liquid crystal, a longitudinal (major) axis of a positive (+) liquid crystal molecule is arranged in parallel to the electric field applied to the liquid crystal. Meanwhile, in the negative (−) type liquid crystal, a longitudinal (major) axis of a negative (−) liquid crystal molecule is arranged in perpendicular to the electric field applied to the liquid crystal.

Hereinafter, a related art LCD device will be described with reference to the accompanying drawings.

FIG. 1 illustrates an expanded plan view of a unit pixel of an LCD device according to the related art. FIG. 2 illustrates a cross sectional view along I-I′ of FIG. 1. FIGS. 3A to 3E illustrate cross sectional views of a process for fabricating an LCD device according to the related art.

As shown in FIGS. 1 and 2, the LCD device according to the related art includes a lower substrate 20 and an upper substrate. The lower substrate 20 includes a gate line 21, a data line 24, a pixel electrode 27, and a thin film transistor TFT. The gate line 21 is formed perpendicular to the data line 24, to define a unit pixel region P. Also, the pixel electrode 27 is formed in the unit pixel region P, and the thin film transistor TFT is formed at a crossing of the gate and data lines 21 and 24.

The thin film transistor TFT is comprised of a gate electrode 21 a, a gate insulating layer 22, an active layer 23, a source electrode 24 a, and a drain electrode 24 b. The gate electrode 21 a protrudes from the gate line 21, and the gate insulating layer 22 is formed on an entire surface of the lower substrate 20. Then, the active layer 23 is formed on the gate insulating layer 22 over the gate electrode 21 a. The source electrode 24 a, which protrudes from the data line 24, overlaps one side of the active layer 23. The drain electrode 24 b, which is formed at a predetermined interval from the source electrode 24 a, overlaps the other side of the active layer 23. In addition, an ohmic contact layer 23 a is formed between the active layer 23 and the source electrode 24 a, and between the active layer 23 and the drain electrode 24 b.

Furthermore, a first storage electrode 24 c is formed on the gate insulating layer 22 above a preceding gate line.

A passivation layer 25 is formed on the entire surface of the lower substrate 20 including the thin film transistor TFT. Also, a first contact hole 26 a is formed in a predetermined portion of the drain electrode 24 b, and a second contact hole 26 b is formed in a predetermined portion of the first storage electrode 24 c.

A pixel electrode 27 is formed in the pixel region on the passivation layer 25 such that the pixel electrode 27 is connected with the drain electrode 24 b through the first contact hole 26 a. Also, a second storage electrode 28 is formed by extending the pixel electrode to the preceding gate line including the second contact hole 26 b.

The pixel electrode 27 and the second storage electrode 28 are formed of a transparent conductive metal having a great transmittance of light, for example, indium-tin-oxide ITO.

Although not shown, the upper substrate is formed opposite to the lower substrate 20. The upper substrate includes a black matrix layer, an RGB color filter layer, and a common electrode. The black matrix layer is provided to prevent light from leaking in other portions except the pixel region P. The RGB color filter layer is formed to represent colors, and the common electrode is formed to realize images.

A method for fabricating the LCD device according to the related art will be described as follows.

First, as shown in FIG. 3A, a conductive metal is coated on the transparent lower substrate 20, and is then patterned by photolithography using a first mask. As a result, the gate line 21 is formed in one direction on the lower substrate 20. In this state, the gate electrode 21 a is formed at one side of the gate line 21.

After that, as shown in FIG. 3B, the gate insulating layer 22 is formed on the entire surface of the lower substrate 20 including the gate line 21. At this time, the gate insulating layer 22 may be formed of silicon nitride SiN_(x) or silicon oxide SiO₂.

After that, a semiconductor layer (mixture of amorphous silicon and impurity amorphous silicon) is formed on the gate insulating layer 22.

Subsequently, the semiconductor layer is patterned by photolithography using a second mask. Thus, the active layer 23 of an island shape is formed above the gate electrode 21 a.

After that, as shown in FIG. 3C, a conductive metal is deposited on the entire surface of the lower substrate 20 including the active layer 23, and is then patterned by photolithography using a third mask. As a result, the data line 24 is formed perpendicular to the gate line 21, the source electrode 24 a which protrudes from one side of the data line 24 overlaps one side of the active layer 23, and the drain electrode 24 b overlaps the other side of the active layer 23. At this time, the drain electrode 24 b is formed at a predetermined interval from the source electrode 24 a. Also, the first storage electrode 24 c is formed above a predetermined portion of the preceding gate line 21.

When etching the data line 24, the source electrode 24 a, and the drain electrode 24 b, the impurity amorphous silicon is over-etched. Thus, the ohmic contact layer 23 a is formed between the source electrode 24 a and the active layer 23, and between the drain electrode 24 b and the active layer 23.

In the above process, the gate line 21 is formed perpendicular to the data line 24, thereby defining the pixel region P.

As shown in FIG. 3D, the passivation layer 25 is deposited on the entire surface of the lower substrate 20 including the data line 24. Subsequently, the first and second contact holes 26 a and 26 b are formed to expose the drain electrode 24 b and the first storage electrode 24 c, respectively.

Referring to FIG. 3E, a transparent conductive layer is deposited on the passivation layer 25, and is selectively removed by photolithography using a fifth mask, thereby forming the pixel electrode 27 in the pixel region. The pixel electrode 27 of the transparent conductive layer extends to the preceding gate line including the second contact hole 26 b, thereby forming the second storage electrode 28.

Through the above-mentioned process according to the related art, the five masks are totally required so that it has a limitation in improvement of yield.

SUMMARY OF THE INVENTION

Accordingly, the present invention is directed to an LCD device and a method for fabricating the same that substantially obviates one or more problems due to limitations and disadvantages of the related art.

An advantage of the present invention is to provide an LCD device and a method for fabricating the same to improve a yield by decreasing a process time.

Additional advantages and features of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. These and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.

To achieve these and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, an LCD device includes gate and data lines formed substantially perpendicular to each other on a substrate and defining a unit pixel region; a thin film transistor formed at a crossing of the gate and data lines; an active layer formed over the gate line, the data line, and the thin film transistor; an organic resin formed on a portion of a gate insulating layer not including the gate line, the data line, and the thin film transistor; a passivation layer formed on an entire surface of the substrate including the thin film transistor; and a pixel electrode, formed in the unit pixel region and connected with a drain electrode of the thin film transistor.

In another aspect of the present invention, a method for fabricating an LCD device includes forming a gate line including a gate electrode on a substrate; forming a gate insulating layer on the substrate including the gate line; forming a data line substantially perpendicular to the gate line and defining a unit pixel region, wherein source and drain electrodes respectively overlap both sides of the gate electrode; forming an insulating organic resin on a portion of the gate insulating layer not including the gate electrode, the gate line, the data line, the source electrode, and the drain electrode; forming an active layer on portions of the substrate except the organic resin; forming a passivation layer on an entire surface of the substrate including the data line; and forming a pixel electrode in the pixel region, wherein the pixel electrode being contacts the drain electrode.

It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification; illustrate embodiments of the invention and together with the description serve to explain the principle of the invention. In the drawings:

FIG. 1 illustrates an expanded plan view of a unit pixel of an LCD device according to the related art;

FIG. 2 illustrates a cross sectional view along I-I′ of FIG. 1;

FIGS. 3A to 3E illustrate cross sectional views of a process for fabricating an LCD device according to the related art;

FIG. 4 illustrates an expanded plan view of a unit pixel of an LCD device according to an embodiment of the present invention;

FIG. 5 illustrates a cross sectional view along II-II′ of FIG. 4;

FIGS. 6A to 6E illustrate cross sectional views of a process for fabricating an LCD device according to an embodiment of the present invention; and

FIGS. 7A to 7E illustrate plan views for a process of fabricating an LCD device according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.

Hereinafter, an LCD device and a method for fabricating the same according to the present invention will be described with reference to the accompanying drawings.

First, an LCD device according to the present invention will be described.

FIG. 4 illustrates an expanded plan view of a unit pixel of an LCD device according to an embodiment of the present invention. FIG. 5 illustrates a cross sectional view along II-II′ of FIG. 4.

As shown in FIG. 4 and FIG. 5, a gate line 61 and a data line 63 are formed on a lower substrate 60, wherein the gate line 61 is formed substantially perpendicular to the data line 63 to define a unit pixel region P. Then, a pixel electrode 68 is formed in the unit pixel region P, and a thin film transistor TFT is formed at a crossing of the gate and data line 61 and 63.

The thin film transistor TFT is comprised of a gate electrode 61 a, a gate insulating layer 62, a source electrode 63 a, a drain electrode 63 b, and an active layer 65. The gate electrode 61 a protrudes from the gate line 61, and the gate insulating layer 62 is formed on an entire surface of the lower substrate 60. Also, the source electrode 63 a which protrudes from the data line 63 overlapped with one side of the gate electrode 61 a. The drain electrode 63 b is overlapped with the other side of the gate electrode 61 a. The source electrode 63 a is formed at a predetermined interval from the drain electrode 63 b. Then, the active layer 65 is formed over the gate electrode 61 a, the source electrode 63 a, and the drain electrode 63 b.

The active layer 65 is formed in correspondence with the gate line 61, the gate electrode 61 a, the data line 63, the source electrode 63 a, and the drain electrode 63 b.

The active layer 65 is formed of an organic semiconductor material such as pentacene and a nano-semiconductor material floating in a predetermined liquid.

Also, an insulating organic resin 64 is coated on the gate insulating layer 62 except the active layer 65. The insulating organic resin 64 is hardened by UV irradiation. For example, the insulating organic resin 64 is formed by hardening acryl base or epoxy base.

Then, a first storage electrode is formed on the gate insulating layer 62 above preceding gate line.

After that, a passivation layer 66 is formed on the entire surface of the lower substrate 60 including the thin film transistor TFT. Also, the passivation layer 66 and the active layer 65 are etched in the predetermined portions of the drain electrode 63 b and the first storage electrode 63 c, thereby forming first and second contact holes 67 a and 67 b.

Also, the active layer 65 and the passivation layer 66 which are formed above the gate line 61 adjacent to the data line 63 are also etched and patterned. By removing the active layer 65 formed above the gate line 61 adjacent to the data line 63, it is possible to remove noise caused between each data line 63.

The pixel electrode 68 is formed on the passivation layer 66 in correspondence with the pixel region. Also, the pixel electrode 68 is connected with the drain electrode 63 b through the first contact hole 67 a.

Also, a second storage electrode 68 b is formed by extending the pixel electrode 68 to the preceding gate line, for being connected with the first storage electrode 63 c through the second contact hole 67 b.

At this time, the pixel electrode 68 and the second storage electrode 68 a are formed of transparent conductive metal having a great light transmittance, for example, indium-tin-oxide ITO, tin-oxide TO, indium-zinc-oxide IZO, or indium-tin-zinc-oxide ITZO.

Although not shown, an upper substrate is formed opposite to the lower substrate. The upper substrate includes a black matrix layer for preventing light leakage in other portions except the pixel region P, an RGB color filter layer for representing colors, and a common electrode for realizing images.

A method for fabricating the LCD device according to the present invention will be described as follows.

FIGS. 6A to 6E illustrate cross sectional views of a process for fabricating the LCD device according to an embodiment of the present invention. FIGS. 7A to 7E illustrate plan views for a process of fabricating the LCD device according to the embodiments of the present invention.

First, as shown in FIG. 6A and FIG. 7A, a conductive metal is deposited on the transparent lower substrate 60, and is then patterned by photolithography using a first mask, thereby forming the gate line 61 in one direction. The gate electrode 61 a protrudes from one side of the gate line 61.

After that, the gate insulating layer 62 is formed on the entire surface of the lower substrate 60 including the gate line 61. The gate insulating layer 62 may be formed of silicon nitride SiN_(x) or silicon oxide SiO₂.

Then, a conductive metal is deposited on the gate insulating layer 62, and is then patterned by photolithograph using a second mask, thereby forming the data line 63, the source electrode 63 a, and the drain electrode 63 b. The data line 63 is formed substantially perpendicular to the gate line 61. Also, the source electrode 63 a which protrudes from one side of the data line 63 overlaps one side of the gate electrode 61 a. The drain electrode 63 b overlaps the other side of the gate electrode 61 a, wherein the drain electrode 63 b is formed at a predetermined interval from the source electrode 63 a. At this time, the first storage electrode 63 c is formed on the predetermined portion of a preceding gate line 61.

In the above-mentioned process, the gate line 61 is formed substantially perpendicular to the data line 63, thereby defining the unit pixel region P.

Referring to FIG. 6B and FIG. 7B, an insulating organic resin 64, which is a solution hardened by UV irradiation, is coated on the entire surface of the lower substrate 60 including the data line 63. For example, acryl base or epoxy base may be coated on the entire surface of the lower substrate 60 including the data line 63. The insulating organic resin 64 is transparent, and is a negative type in which the predetermined portion irradiated with UV rays remains.

Next, as shown in FIG. 6C and FIG. 7C, the coated organic resin 64 is irradiated with UV rays from a rear surface of the lower substrate 60.

As applying UV rays to the rear surface of the lower substrate, the organic resin 64 positioned over the gate line 61, the gate electrode 61 a, the data line 63, the source electrode 63 a, and the drain electrode 63 b is not hardened since it is not irradiated with UV rays, and the organic resin of the remaining portions is hardened.

After that, the organic resin 64 which is not hardened by UV rays is removed.

Subsequently, as shown in FIG. 6D and FIG. 7D, a liquid material, which is formed of a solvent having a semiconductor material dispersedly floating, is coated on the entire surface of the lower substrate 60. At this time, the liquid material includes an organic semiconductor such as pentacene.

The liquid material is coated only on a surface having a hydrophilic property except the organic resin 64 having a hydrophobic property. Then, a heat treatment is performed to the coated liquid material. Thus, the solvent is vaporized, and only the semiconductor material remains. As a result, the active layer 65 is formed over the gate line 61, the gate electrode 61 a, the data line 63, the source electrode 63 a, and the drain electrode 63 b.

After that, as shown in FIG. 6E and FIG. 7E, the passivation layer 66 is deposited on the entire surface of the lower substrate 60 including the active layer 65. At this time, the passivation layer 66 may be formed of at least any one of oxide, nitride, photo acryl, polyimide, and BenzoCycloButene BCB.

Subsequently, the passivation layer 66 is patterned by photolithograph using a third mask, thereby forming the first and second contact holes 67 a and 67 b for respectively exposing the predetermined portions of the drain electrode 63 c and the first storage electrode 63 c.

When forming the first and second contact holes 67 a and 67 b, the active layer 65 and the passivation layer 66 positioned above the gate line 61 adjacent to the data line 63 are also removed. As a result, it is possible to minimize noise caused by the active layer adjacent to the data line 63.

After that, a transparent conductive layer is deposited on the passivation layer 66, and is selectively removed by photolithograph using a fourth mask, thereby forming the pixel electrode 68 in the pixel region P.

The transparent conductive layer is connected with the first storage electrode 63 c through the second contact hole 67 a. Also, the transparent conductive layer extends to the preceding gate line including the first storage electrode 63 c, thereby forming the second storage electrode 68 a.

According to the above-mentioned method, it is possible to form a storage-on-gate structure of a storage capacitor.

The transparent conductive layer may be formed of indium-tin-oxide ITO, tin-oxide TO, indium-zinc-oxide IZO, or indium-tin-zinc-oxide ITZO.

Although not shown, an alignment layer is formed on the entire surface of the lower substrate 60 including the pixel electrode 68. The alignment layer may be formed of a photo-alignment material or polyimide.

If the alignment layer is formed of polyimide, an alignment direction thereof is determined by a mechanical rubbing method. If the alignment material is formed of a photo-alignment material such as a polyvinylcinnamate-based material) or a polysiloxane-based material, an alignment direction thereof is determined by UV irradiation. At this time, the alignment direction is determined depending on the direction and property of light irradiated, that is, a polarizing direction.

As mentioned above, the LCD device and the method for fabricating the same according to the present invention have the following advantages.

In the method for fabricating the LCD device according to the present invention, the active layer can be formed by exposure of the rear surface and the liquid material without a mask. Accordingly, it is possible to obtain a simplified process with a decreased number of masks, thereby improving the yield.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. 

1. A method for fabricating an LCD device comprising: forming a gate line including a gate electrode on a substrate; forming a gate insulating layer on the substrate including the gate line; forming a data line substantially perpendicular to the gate line and defining a unit pixel region, wherein source and drain electrodes respectively overlap both sides of the gate electrode; forming an insulating organic resin on a portion of the gate insulating layer not including the gate electrode, the gate line, the data line, the source electrode, and the drain electrode, by exposure of the rear surface of the substrate, not using a mask, after forming the data line and the source and drain electrodes; forming an active layer on entire surfaces of the gate electrode, the gate line, the data line, the source electrode, and the drain electrode, except the organic resin; forming a passivation layer on an entire surface of the substrate including the data line; and forming a pixel electrode in the pixel region, wherein the pixel electrode contacts the drain electrode.
 2. The method of claim 1, wherein the step of forming an insulating organic resin comprises, coating the insulating organic resin, which is hardened by UV irradiation, on the entire surface of the substrate; applying UV rays to a rear surface of the substrate by using the gate electrode, the gate line, the data line, the source electrode, and the drain electrode as a mask; and removing the insulating organic resin not hardened by the UV irradiation.
 3. The method of claim 1, wherein the insulating organic resin is formed of acryl base or epoxy base.
 4. The method of claim 1, wherein the step of forming an active layer comprises: coating a liquid material, which is a solvent having a semiconductor material dispersedly floating, on the entire surface of the substrate; and performing a heat treatment to the coated liquid material to vaporize the solvent.
 5. The method of claim 4, wherein the liquid material includes an organic semiconductor material including pentacene.
 6. The method of claim 1, wherein the passivation layer is formed of at least one of oxide, nitride, photo acryl, polyimide, and BenzoCycloButene (BCB).
 7. The method of claim 1, further comprising forming a first storage electrode in a predetermined portion above a preceding gate line, wherein the first storage electrode is formed with when forming the data line, the source electrode, and the drain electrode.
 8. The method of claim 7, further comprising forming first and second contact holes for respectively exposing predetermined portions of the drain electrode and the first storage electrode by patterning the passivation layer.
 9. The method of claim 8, wherein the active layer and the passivation layer positioned over the gate line adjacent to the data line are removed when forming the first and second contact holes.
 10. The method of claim 8, further comprising forming a second storage electrode extending from the pixel electrode to the preceding gate line, wherein the second storage electrode is connected with the first storage electrode through the second contact hole, when forming the pixel electrode. 